MINISTRY OF DEFENCE / DGQA STANDARD QUALITY … Gear Rev -01.pdf · 2 ASTM E 446 RT for steel...

MINISTRY OF DEFENCE / DGQA

STANDARD QUALITY ASSURANCE PLAN

STEERING GEAR SYSTEM

STEERING GEAR SYSTEM IS USED FOR STEERING THE SHIP TO THE DESIRED COURSE AT ALL SPEEDS. THE SYSTEM COMPRISES OF TWO HYDRAULICALLY OPERATED RUDDERSTOCKS, MECHANICALLY LINKED TOGETHER AND DUAL HYDRAULIC POWER UNITS CONNECTED VIA A COMMON DISTRIBUTION VALVE BLOCK TO THE RUDDER OPERATING CYLINDER AND OTHER EQUIPMENT FOR NORMAL FUNCTIONING. STEERING GEAR IS CONTROLLED AND MONITORED FROM BRIDGE AND OPS ROOM IN FOLLOW UP MODE, NON- FOLLOW UP MODE & AUTO PILOT MODE

STANDARD QAP NO. DGQA/DQA (WP)/STRG GEAR/01/2018/REV-01

07 AUG 2018

Total Nos. of Pages: 61

ISSUING AUTHORITY

DIRECTORATE OF QUALITY ASSURANCE (WARSHIP PROJECTS)

'H' BLOCK, NIRMAN BHAWAN P.O

NEW DELHI - 110 011

MINISTRY OF DEFENCE / DGQA STEERING GEAR SYSTEM PAGE 02

DIRECTORATE OF QUALITY ASSURANCE (WARSHIP PROJECTS) NEW DELHI - 110 011

SQAP NO. DGQA/DQA(WP)/ STRG GEAR /01/2018/REV 01

REV. NO. 01

DATE 07 AUG 18

RECORD OF AMENDMENTS

Sl.

No.

Date of

Amendment

Amendments Authority Remarks




REV. NO. 01

DATE 07 AUG 18

CONDITIONS OF RELEASE

1. This Standard Quality Assurance Plan (SQAP) has been formulated for reference of the Order Placement Agencies, Inspection Authority, Inspection Agencies and the Industry. No alteration is to be made to this SQAP except by the issue of authorised amendment by DQA (WP). 2. It is to be applied, as required, for Quality Assurance during various stages of manufacture of Steering Gear System for IN Ships. 3. The website htpp://www.dgqadefence.gov.in may also be referred for other Quality Assurance related inputs. 4. The SQAP has been prepared on the basis of decisions made during the collegiate meeting held at DQA(WP) with leading manufacturers of Steering Gear System and representatives of Professional Directorates and Production Directorates of the IN. Any user of this Standard QAP within DGQA / IN or in industry may propose an amendment to it with valid justification. Proposals not applicable to particular contract can be sent directly to DQA (WP), New Delhi, and those directly applicable to a particular contract are to be dealt with using contract procedures. 5. The specifications and standards laid out in the SQAP are indicative only. The specifications / parameters and standards given in the Statement of Technical Requirement (SOTR) / Technical Specifications (TSP) / MoM of TNC / Approved drawings will be final and binding. 6. DQA(WP) reserves the right to amend or modify the contents of this SQAP without consulting or informing any holder of this document. 7. In case the SQAP is incorporated into contracts, users are responsible for their correct application while complying with contractual and other statutory requirements. Compliance with SQAP does not of itself confer immunity from legal obligations. 8. Enquiries in connection to these requirements may be made from:

Directorate of Quality Assurance (Warship Projects)

Ministry of Defence

'H' Block, Nirman Bhawan P.O

New Delhi - 110 011




REV. NO. 01

DATE 07 AUG 18

CONTENTS

SL. NO. DESCRIPTION PAGE

1. Standards Invoked 06

2. Specific Requirements 08

3. Abbreviations 10

4. Scope 11

5. System Description 12

6. Part-I: General Information 13

7. Part-II : Technical Inspection/Trials 13

APP 'A' Standard QAP of Steering Gear (Hydro-Mech) 14

APP 'B' Standard QAP of Motor 44

APP 'C' Standard QAP of AC Starter & Control Panel 48

APP 'D'. Standard QAP of Control System 53

APP ‘E’ Standard QAP for Multipoint Lubrication Pump Assembly 58




REV. NO. 01

DATE 07 AUG 18

STANDARDS INVOKED

SL. NO. SPECIFICATION DESCRIPTION

1 AISI, SS 316 Specification for steel material.

2 ASTM E 446 RT for steel castings up to 2 inch thickness

3 ASTM E 186 RT for heavy walled steel castings

4 ASTM E 272 RT for Copper based and Nickle Copper Alloy castings

5 ASTM E 1320 Standard reference radiographs for Titanium casting

6 ASTM E 1032 Std. test method for radiographic examination of

weldments

7 ASTM A 743 Std. specification for castings, Iron-Chromium, Iron-

Chromium-Nickle, corrosion resistant for general

application

8 ASTM A 609 Std. practice for performing pulse-echo ultrasonic

examination

9 ASTM E 165 Std. practice for liquid penetrant examination

10 ASTM E 125 Std. reference photographs for MPI in ferrous

castings

11 ASTM A 148 Std. specs for steel castings, high strength for structural purposes

12 ASTM A 217 Std. specs for steel castings Martensitic Stainless & Alloy for pressure containing parts

13 ASTM A 216 Std. specs for steel castings suitable for fusion

welding

14 ASME Sec IX Qualification Standard for welding, brazing & fusing procedures

15 ASME Sec V Non-destructive examination

16 ASME Sec VIII Rules for construction of pressure vessels

17 ASME Sec II Part A Ferrous material specifications

18 ASME Sec II Part B Non-ferrous material specifications

19 BS 1400 Copper alloy ingots and copper alloy and high

conductivity copper castings

20 BS 4670 Specification for alloy steel forging

21 BS 2871:Part 2 Copper & Copper alloy tubes

22 EN 10250-2 Open die steel forging

23 SA 105 Specification for Carbon Steel Forging

24 IS 2062 Hot medium & high tensile structural steel

25 AISI SS 316 Specification for steel material

26 DMR 249/D40S Structural steel

27 Def Stan 02-797 Part-4 Carbon steel fittings / Pipe work engineering




REV. NO. 01

DATE 07 AUG 18

28 Def Stan 02-339 Requirement for steering and stabilizer system

29 Def Stan 02-477 Flexible hoses

30 Def Stan 61.5 Electric power supply system

31 EED-Q-071(R4) Specification for AC motors and starters / control gears

32 ISO 2372 Specification for vibration test.

33 JSS 55555 Environmental test methods for electrical & electronic

eqpt

34 NES 340 Stabilisers

35 NES 375 Valve design & manufacture

36 BR3021 Shock Testing

37 MIL-STD-740-2 SBN measurement & acceptance criteria of shipboard

equipment

38 MIL-STD-167-1 Mechanical vibrations of shipboard equipment

39 MIL-STD-1474D Design criteria standard, noise limits

40 MIL-STD-461F EMI / EMC

Note:- The Standards given are indicative only. The specifications / standards given in the

SOTR / Technical Specifications (TSP) / MoM of TNC / Approved drawings will be final

and binding.




REV. NO. 01

DATE 07 AUG 18

SPECIFIC REQUIREMENTS 1. Testing of physical and chemical properties has to be done by NABL accredited laboratory only (including firm's NABL accredited laboratory). 2. If casting is being poured without integral test bar, then only the pouring is to be witnessed by Inspector. 3. All castings are to be subjected to RT and / or UT, as applicable, to qualify the same in accordance with the approved class of casting, unless otherwise specified in P.O. & SOTR / TSP. The extent of RT will be as per the approved drawing. The class of casting is to be invariably mentioned in the drawing / DBOM. 4. All forgings are to undergo UT for soundness and integrity checks. 5. All tubes / pipes are to be subjected to Eddy Current test unless exempted in PO / TEC. 6. Shooting sketch indicating critical test zones and test zones are to be submitted prior to testing. 7. NDT procedure to be approved by ASNT / ISNT Level III qualified person based on standards and acceptance criteria specified in SOTR / TSP / applicable standards and performed by ASNT / ISNT Level II / Level III qualified person. 8. Make of the Items should be as per approved PIL / Detailed Bill of Material (DBOM) or IN approved sources. 9. The outsourced components in the SQAP are indicative only. OEM is to categorize the outsourced components, specific to their product, in the QAP as per the approved DBOM / Drawings and in accordance with Chapter-5 of QAD-01 R01. . 10. Imported items will be accepted against following import documents:-

(a) Bill of Lading / Shipping Bill / Airway Bill (b) Invoice by OEM or Country of Origin Certificate with Packing List (c) Bill for entry to warehousing (d) OEM Confirmation Certificate (e) Firm’s Guarantee certificate as per SOs

11. ESS test (Thermal Cyling, Random Vibration and Burn in / Endurance) as per

DQA(N) policy vide letters 66301/Policy-07/DQA(N)/QA-07 dated 09 Aug 16.

12. Ingress protection testing will be as per applicable IP rating.




REV. NO. 01

DATE 07 AUG 18

13. TT, EMI / EMC Test and ET will be done at Government / PSU test centers or NABL accredited labs. EMI/EMC Acceptance Test Plan is to be duly vetted by NEC Mumbai. 14. If TT, EMI/EMC and ET have already been done in earlier projects on identical units, it will not be done again & the reports of earlier tested units will have to be provided for review of Inspection Agency.

15. Conformal coating of PCBs to be done as per DQA(N) policy letter 580930/DQA(N)/EL dated 17 Feb 14. 16. Bought-out items will be subjected to normal QA inspections as per QAP.

17. Since the Steering Gear System is to be subjected to IFATs, the draft Operating Instructions, Technical Documentation and firm’s in-house test report is to be made available prior to raising request for conduct of the same.




REV. NO. 01

DATE 07 AUG 18

ABBREVIATIONS

VI Visual Inspection

DI Dimensional Inspection

LTC Lab Test Certificate

STC Supplier Test Certificate

MTC Material Test Certificate

CC Conformance / Compliance Certificate

CHP Customer Hold Point

IR Inspection Report

NABL National Accreditation Board for Testing and Calibration of Laboratories

P Perform

R Review

V Verification

W Witness

TC Test Certificate

OEM Original Equipment Manufacturer

DPT Dye Penetrant Test

MPT Magnetic Particle Test

SBN Structure Borne Noise

ABN Air Borne Noise

FATs Factory Acceptance Trials

PQR Procedure Qualification Record

WPS Welding Procedure Specification

WPQ Welder Performance Qualification

ET Environmental Testing

EMI Electro Magnetic Induction

EMC Electro Magnetic Conduction

ESS Environment Stress Screening

ASNT American Society of Non-destructive Testing

ISNT Indian Society of Non-destructive Testing

VME Versa Module Europa

TT Type Test

TSP Technical Specifications

SOTR Statement of Technical Requirement

DBOM Detailed Bill of Material

QA Quality Assurance




REV. NO. 01

DATE 07 AUG 18

SCOPE

1. Scope of Quality Assurance. The scope of QA includes witness / review at all

stages of manufacturing viz., raw material stage, in-process stage and final stage. The

scope also covers witness / review of Type Testing, wherever applicable.

2. The SQAP contains comprehensive list of inspections and/or trials that are

applicable for QA of the equipment. In addition, QA of the equipment will also be

governed by specific conditions laid down in SOTRs and ‘Approved Drawings’. The

inspections / tests / trials must be contemporary to latest technology / techniques

available in the industry at the time of placement of purchase order.

3. The following QA activities will be carried out for the Steering Gear System:-

(a) Visual Inspection.

(b) Dimensional Inspection.

(c) Witness of pouring in absence of integral test bar.

(d) Review of Lab Test Certificates.

(e) Witness of in-house Lab Testing, if applicable.

(f) Witness of Non-destructive Testing viz. UT, DPT & MPT.

(g) Witness of Eddy Current Test or review of Eddy Current Test Report, as

applicable.

(h) Review of RT films and reports.

(j) Review of Heat Treatment Charts.

(k) Witness of Endurance Trials & Tilt Test and Review of Shock Test and SBN

& ABN reports for qualification of Type Test, as applicable.

(l) Review of ET, EMI/EMC and ESS reports, in addition to Pre / Post ET

inspection, as applicable.

(m) Review of Draft documentation and witness/Stamping of final

documentation, as applicable.

(n) Issue of CHP clearance.

(p) Issue of Dispatch Clearance or Issue of Form-IV, as applicable.




REV. NO. 01

DATE 07 AUG 18

SYSTEM DESCRIPTION

1. The Steering gear system is for steering the ship to the required course at all

speeds in Auto, Follow-up and Non-follow-up modes. The twin rudder fitted on the ship is

used to achieve required course.

2. The system comprises of two hydraulically operated rudderstocks, mechanically

linked together, and dual hydraulic power units, connected via a common distribution

valve block to the rudder operating cylinders. The steering gear is capable of moving the

rudder hard over through full range of 35-0-35 degrees in 28 seconds. With ship doing full

ahead at 33 Knots & both hydraulic power packs in use, the Steering Gear is capable of

turning, stopping and holding the rudder at any angle over a range of 35 degrees either

side of the midship.

3. Steering Gear is controlled & monitored from Bridge, OPS Room or in emergency

mode from the hydraulic power pack located in Steering Gear compartment (Local Control

Post)

STEERING GEAR SYSTEM

Mechanical System Hydraulic System Control System

Rudderstock Power Pack Bridge & OPS Console

Rudder Assembly Electric Motor Command Selection Box

Cartridge Structure Isolation Manifold Rudder Servo Amplifier Unit

Inboard Bearing Distribution Block Rudder Feedback unit

Sleeve Bearing Overhead Oil Tank MCR Unit

Tiller Reserve Oil Tank Rudder Angle Indicator

Lock Pin Assembly Emergency Hand Pump Rudder angle transmitter

Ram Pin Assembly Lubrication Unit Junction Box

Synchronizing link ACOS

MSP




REV. NO. 01

DATE 07 AUG 18

STANDARD QUALITY ASSURANCE PLAN

Part - I. General Information

1. The following generic information must generally be provided on each QAP as its

identity:-

(a) Equipment name

(b) Equipment technical details (as applicable)

(c) Purchase Order reference

(d) Sub/Sub-Sub Orders reference (as applicable)

(e) Name of Main Indenter/ Ordering Authority

(f) Name of end user

(g) Name of firm / manufacturer

(h) SOTRs reference

(j) Yard No./ Name of ship where to be fitted (if available) / End user

(k) References of relevant drawings

(l) QAP No. & Date (as indicated by the firm)

(m) Contractual delivery date

(n) Inspection Authority

(p) Inspection Agency

(q) Quantity (as applicable)

Part - II.

Standard QAP of Steering Gear (Hydro-Mech) Appendix "A"

Standard QAP of Motor Appendix "B"

Standard QAP of AC Starter & Control Panel Appendix "C"

Standard QAP of Control System Appendix "D"

Standard QAP of Multipoint Lubrication Pump Assembly Appendix "E"

14

Appendix - 'A' Refers to Part-II of SQAP

STANDARD QUALITY ASSURANCE PLAN FOR STEERING GEAR SYSTEM

SL. NO.

MATERIAL / COMPONENT /

DRG.NO / QUALITY ACTIVITY

QTY AS

PER P.O.

CHARACTERISTICS / TYPE OF CHECK

QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

1.0.0 DRAWINGS / DOCUMENTS VERIFICATION

1.1.0 GA Drawings along with DBOM & Binding Data

Check for availability of approved drawings and DBOM & Binding Data

100% PO & SOTR/ TNC Minutes

All approved drawings along with DBOM & Binding Data are available

List of approved drawings & Binding Data

CHP for R

Approved binding data / drawing to be verified

1.2.0 Manufacturing Drawings

Verification of manufacturing drawings with reference to approved GA drawings and DBOM for completeness and sufficiency of data to undertake production and process inspections.

100% SOTR, GA Drawings along with DBOM

Manufacturing drawings bear complete data; The data is sufficient for production and stage inspections

List of approved drawings

CHP for R

--

1.3.0 Type Test / ET / EMI/EMC reports

Availability & verification 100% PO & SOTR / TNC Minutes/ JSS 55555

Equipment should be tested in the past and relevant certificate is available

Type/ Qualification test reports

CHP for R

Type / qualification test are to be conducted if not undertaken earlier or test certificate not held or equipment has undergone changes

2.0.0 MATERIAL INSPECTION

2.1.0 RUDDER BEARING ARRANGEMENT ASSEMBLY (DRG. NO…………….…)

2.1.1

Lower Bearing Housing and Upper Bearing Housing [Inboard Bearing Housing and Outboard Bearing Housing] (Steel Casting)

(i) Pouring with integral test bar

100% SOTR, Approved GA drawing, DBOM and manufacturing drawings

Conformity to specifications

IR R If casting is without integral test bar, pouring to be witnessed by QAO

(ii) Material identification & stamping

100% Conformity to specifications

IR W

(iii) Heat Treatment


HT Report R

(iv) Mechanical properties and Chemical Composition

01 test piece/ lot / heat


LTC R Testing to be done at NABL approved laboratory.

15


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

(v) U.T 100% Defects within permissible limits as per applicable standards / specs

NDE Report

CHP for W

Testing to be do done by ISNT / ASNT Level II or III qualified technician

(vi)MPT / DPT on machined surfaces

100% NDE Report

CHP for W

(vii) RT Critical Regions

NDE Report

CHP for R

2.1.2 Rudder Stock [Steel Forging]

(i) Heat treatment 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings


HT Report R

(ii) Stamping & test piece identification


IR W

(iii) Mechanical properties and Chemical Composition




(iv) U.T 100% Defects within permissible limits as per applicable standards / specs

NDE CHP for W


(v) MPT / DPT on machined surfaces

100% NDE CHP for W

2.1.3 Rudder Stock Bearing Sleeve (Upper and Lower)






IR W





(iv)U.T followed by Pressure Test

100% Defects within permissible limits as per applicable standards / specs

NDE Report

CHP for W

Testing to be do done by ISNT/ ASNT Level II or III qualified technician


100% NDE Report

CHP for W

(vi) RT Critical Regions

NDE Report

CHP for R

2.1.4 Inboard Bearing & Outboard Bearing (Lower Bearing and Upper Bearing)


100% SOTR, Approved GA drawing, DBOM and


IR R If casting is without integral test bar, pouring to be witnessed by QAO.

16


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

(Casting) (# Import substitute are listed at Sl 3.1.1)


100% manufacturing drawings


IR W





(iv)U.T followed by Pressure Test


NDE Report

CHP for W

Testing to be do done by ISNT/ ASNT Level II or III qualified technician

(v)MPT / DPT on machined surfaces

100% NDE Report

CHP for W

(vi) RT Critical Regions

NDE Report

CHP for R

2.1.5 (a) Thrust Bearing (b) End Piece (c) Spacer (Cu Alloy Casting)







IR W






NDE Report

CHP for W


(v) DPT on machined surfaces

100% NDE Report

CHP for W

(vi) RT Critical regions

NDE Report

CHP for R

2.1.6 Tiller (Steel Casting)






IR W

(iii) Heat Treatment 100% Conformity to specifications

HT Report R




LTC R Testing to be done at NABL approved lab.

(v) U.T 100% Defects within NDE CHP for Testing to be do done

17


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

permissible limits as per applicable standards / specs

Report W by ISNT/ ASNT Level II or III qualified technician

(vi)MPT / DPT on machined surfaces

100% NDE Report

CHP for W

(vii) RT Critical regions

NDE Report

CHP for R

2.1.7 Gland Follower (SG Iron Casting)







IR W

(iii) Heat Treatment 100% Conformity to specifications

HT Report R





(v) UT 100% Defects within permissible limits as per applicable standards / specs

NDE Report

CHP for W


(vi) MPT / DPT on machined surfaces

100% NDE Report

CHP for W

(vii ) RT Critical regions

NDE Report

CHP for R

2.1.8 (a) Lock Nut - Tiller (b) Stud (for Lock Nut - Tiller) (c) Stud for gland follower (Steel Forging) (d) Key - Tiller

(i) Material identification & stamping


IR W

(ii) Mechanical properties and Chemical Composition



(iii) UT (for Lock nut and Key only)


NDE Report

CHP for W

Testing to be done by ISNT / ASNT Level II or III qualified technician

2.1.9 Hull Cartridge Structure (Rolled steel Plates)



IR W Review of mill TC duly cleared by CQAE(NS) as per NCD 0249




LTC / CQAE(NS) report

R Testing to be done at NABL approved laboratory.

18


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

2.1.10 Rudder (Rolled Steel Plates)




IR W




LTC / CQAE(NS) report

R Testing to be done at NABL approved laboratory.

2.1.11 Keep plate (Structural Steel)


11 100% Conformity to specifications

IR W




CC R

2.1.12 Rudder Angle Transmitter and Feed Back Units- (a) Feed Back Lever (MS) (b) Transmitter Lever (MS) (c) Pins (Alloys Steel)



IR W





2.1.13 Feed Back Unit Support



IR W





2.1.14 Connecting Rod (i) Material identification & stamping


IR W





2.1.15 Mechanical Locking Pin Assembly (a) Locking Pin (Alloy Steel) (b) Screw-Locking Pin (MS) (c) Top Plate (Structural Steel) (d) Stud Top Plate (MS)

(i)Material identification & stamping


IR W





19


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

(e) Collar (Structural steel)

2.2.0 SYNCHRONISING LINK TUBE ASSEMBLY (DRG. NO.______)

2.2.1 Link Tube (Steel)




IR W




(iii) U.T 100% Defects within permissible limits as per applicable standards / specs

NDE Report

CHP for W

Testing to be do done by ISNT/ ASNT Level II or III technician

2.2.2 Link end L.H. & R.H. (Steel Forging)



IR W




LTC R Testing to be done at NABL approved laboratory


NDE Report

CHP for W

Testing to be done by ISNT/ASNT Level II or III qualified technician

2.2.3 (a) Bearing Retainer (Alloy Steel) (b) Locking Plate (Structural Steel)



IR W





2.2.4 Bearing Pin (ForgedSteel)



IR W





2.2.5 Support Plate for Bearing Pin



IR W





2.2.6 Link Tube Support Bracket



IR W

(ii)Mechanical properties 01 test Conformity to LTC R Testing to be done at

20


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

and Chemical Composition piece/ lot / heat

specifications NABL approved laboratory

2.3.0 POWER UNIT ASSY (DRG. NO._____________)

2.3.1 Pump & Motor Mounting Bracket (Steel Fabrication)




IR W





2.3.2 Sole Plate (Plates)



IR W


01test piece/ lot / heat


LTC R Testing to be done at NABL approved lab

2.3.3 Manifold block (Forging)



IR W






NDE Report

CHP for W


2.4.0 HYDRAULIC ACTUATOR ASSY/HYDRAULIC CYLINDER & RAM ASSEMBLY (DRG. NO____)

2.4.1 Tube for cylinder / Cylinder Barrel




IR W





(iii) U.T followed by pressure test @ 1.5 times working pressure, 30 mins


NDE Report

CHP for W


2.4.2 Cross Head Ram (Steel Forging)

(i) Heat treatment 100% Conformity to specifications

HT Report R

(ii) Stamping & test piece identification


IR W


01 test piece/ lot /


LTC R Testing to be done at NABL approved

21


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

heat laboratory


NDE Report

W Testing to be done by ISNT/ASNT Level II or III qualified technician (v)MPT / DPT on

machined surfaces 100%

NDE Report

CHP For W

2.4.3 Cylinder Rear End Cover (Fabrication)




IR W

(ii)Mechanical properties and Chemical Composition




2.4.4 Cylinder Front End Cover (Fabrication)



IR W





2.4.5 (a) H- Beam (b) Guide Plate (c) Retainer Plate Pin (d) Cross head pin



IR W





2.4.6 Cod Piece (Copper Alloy Casting)






IR W






NDE Report

CHP for W



100% NDE Report

CHP for W


NDE Report

CHP for R

2.4.7 Bearing Bush / Neck Bush (Cu alloy Casting)


100% SOTR, Approved GA drawing, DBOM


IR R If casting is without integral test bar, pouring to be

22


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

and manufacturing drawings

witnessed by QAO



IR W





(iv)U.T followed by pressure test


NDE Report

CHP for W

Test pressure to be recommended by firm based on design criteria viz. thickness, material & load / pressure etc. for approval. Testing to be done by ISNT/ASNT Level II or III qualified technician

(v)MPT / DPT on machined surfaces

100% Defects within

permissible limits

as per applicable

standards / specs

NDE Report

CHP for W


NDE Report

CHP for R

2.4.8 Steel Plates (Cylinder Base) for fabrication



IR W





2.4.9 Crosshead Slipper (i) Material identification & stamping

100%


IR W


01 test piece / lot



2.4.10 Guide Slipper (i) Material identification & stamping


IR W


01 test piece per lot



2.5.0 SUPPLY TANK ASSY (DRG. NO._____)

2.5.1 Steel Plates for Fabrication


100% SOTR, Approved GA drawing, DBOM and manufacturing


IR W





23


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

drawings

2.6.0 RESERVE OIL TANK ASSEMBLY ( DRG. NO. _____)

2.6.1 Steel Plates for Fabrication




IR W





2.7.0 DISTRIBUTION BLOCK ASSEMBLY (DRG. NO.______)

2.7.1 Manifold Block / Distribution Block (Steel Forging)




IR W






NDE Report

CHP for W

Testing to be done by ISNT/ASNT Level II or III qualified technician (iv) MPT / DPT on

machined surfaces 100% NDE

Report CHP for W

2.8.0 PIPES & FITTINGS (DRG. NO.____)

2.8.1 Cupro-Nickel Pipes (Cu-Ni 70 / 30)




IR W





(iii) Eddy Current test 100% Tubes are free from defects

NDE Report

CHP for W


(iv) Pressure testing (1.5 times working pressure, 30 mins)

100% Pressure Test is satisfactory

IR W

(v) Annealing 100% Conformity to specifications

HT Report R

2.8.2 Hydraulic Hoses and End fittings /

(i) Product Identification


IR W OEM TC to indicate details of Ozone test,

24


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

Connections

(ii) Pressure Test (1.5 times working pressure, 30 mins)


IR CHP for W

oil resistance test & Burst Test for Hoses. Hose register to reflect hose size and shelf life.

2.9.0 LUBRICATION ASSEMBLY (DRG. NO.______)

2.9.1 Brass tube




IR W





(iii) Eddy Current test 100% Tubes are free from defects

NDE Report

CHP for W


(iv) Pressure test at 1.5 times working pressure, 30 mins


IR W

2.10.0 ESP POWER UNIT ASSEMBLY & SUPPLY OIL TANK (DRG NO._______)

2.10.1 Bell Housing (Plates) (i) Material Identification & stamping



IR W





2.10.2 Manifold Block (i) Material Identification & stamping


IR W





(iii) U.T 100% Conformity to applicable standard/ specifications

NDE Report

CHP for W

Testing to be done by ISNT/ASNT Level II or III qualified technician (iv)MPT / DPT on

machined surfaces 100% NDE

Report CHP for W

2.10.3 Steel Plates for Tank Fabrication

(i) Material Identification & stamping


IR W

25


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS


01 test piece / lot



3.0.0 OUTSOURCED COMPONENTS / ITEMS

3.1.0 RUDDER BEARING ARRANGEMENT (DRG. NO.___)

3.1.1 Lower bearing and Upper bearing (Synthetic)

Product identification

100%

SOTR, Approved GA drawing, DBOM and manufacturing drawings / catalogue


OEM TC / CC

R

3.1.2 Seal PTFE Product identification


OEM TC / CC

R

3.1.3 Gland packing Product identification 100% Conformity to specifications

OEM TC / CC

R

3.1.4 Lantern Ring Product identification 100% Conformity to specifications

OEM TC / CC

R

3.1.5 Lifting Hook Product identification 100% Conformity to specifications

STC / CC R

3.1.6 Nyloc Nut Product identification 100% Conformity to specifications

STC / CC R

3.1.7 SOC. HD. Cap Bolt Product identification 100% Conformity to specifications

STC / CC R

3.1.8 Hardware Item (High Grade Alloy Steel)

(i) Product identification 100% Conformity to specifications

OEM TC / CC

R



Properties meet the laid down specifications


3.2.0 LINK TUBE ASSEMBLY / SYNCHRONISING LINK TUBE ASSEMBLY (DRG.NO.__)

3.2.1 Bearing

Product identification 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings / catalogue


OEM TC / CC

R

3.2.2 Spring Feed Lubricator Product identification


OEM TC / CC

R

3.3.0 RUDDER FEED BACK UNIT / SUB COMPONENTS RUDDER BEARING ASSEMBLY (DRG. NO.____)

3.3.1 Feed Back Unit with Potentiometer

(i) Product identification 100% SOTR, Approved GA drawing, DBOM and


OEM TC /CC

R

(ii) Functional check on assembly

100% Functional checks are satisfactory

IR W

26


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

manufacturing drawings / catalogue

3.4.0 POWER UNIT ASSY (DRG. NO____)

3.4.1 Couplings / Flexible Coupling



OEM TC/ CC

R

3.4.2 Pump (i) Product identification. 100% Conformity to specifications

OEM TC /CC

R


100% Functional check should be satisfactory

IR W

3.4.3 Hydraulic Fittings (Passivated)


OEM TC /CC

R

(ii) Pressure Testing (1.5 times working Pressure, 30 mins)


Pressure Test is satisfactory

IR W

3.4.4 O’ Rings & Bonded Seals


OEM TC / CC

R

(ii) Polymer Identification 100% Conformity to specifications


3.4.5 Oil cooler Inspection 100% As per separately approved QAP Form IV / I-note

R

3.4.6 Accumulator Unit (i) Product identification 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings / catalogue


OEM TC / CC

R

(ii) Visual Inspection and Dimensional Inspection


IR R

3.4.7 Servo Filter Product identification 100% Conformity to specifications

OEM TC R

3.4.8 Boost Filter Product identification 100% Conformity to specifications

OEM TC R

3.4.9 Suction Filter Product identification 100% Conformity to specifications

OEM TC R

3.4.10 Pressure Switch Product identification 100% Conformity to specifications. Calibration is indate.

OEM TC & Calibration Certificate

R

27


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

3.4.11 Shock & Vibration Mounts

Inspection 100% As per SQAP / Separately approved QAP

Form IV / I-note

R

3.4.12 Ball Valve (i) Product identification 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings / catalogue


OEM TC/ CC

R

(ii) Pressure Test and Functional Checks on assembly

100% Pressure test and functional checks are satisfactory

IR W

3.4.13 Cartridge Valve


100% SOTR, Approved GA drawing, DBOM and manufacturing drawings / catalogue


OEM TC / CC

R

3.4.14 Cartridge Cover

Product identification 100% Conformity to specifications

OEM TC / CC

R

3.4.15 Solenoid Operated D.C.Valve



OEM TC / CC

R

3.4.16 Quick Change Coupling



OEM TC / CC

R

3.4.17 Check Valve


OEM TC / CC

R

(ii) Functional Checks on assembly


IR W

3.4.18 Accumulator Pressure Gauge

Product identification 100% Conformity to specifications. Calibration is indate.


R

3.4.19 Suction Filter Pressure Gauge

Product identification 100% Conformity to specifications. Calibration is indate.


R

3.4.20 Servo Valve


OEM TC / CC

R



IR W

28


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

3.4.21 Pressure Gauge

(i)Product identification 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings / catalogue

Conformity to specifications Calibration is indate.


R

(ii)Functional Checks on assembly

100% Pressure gauges are functional

IR W

3.4.22 Junction Box

(i) Product identification


OEM TC R


100%

Inspection is satisfactory

IR R

3.5.0 HYDRAULIC ACTUATOR OR CYLINDER RAM ASSEMBLY (DRG. NO. ____)

3.5.1 Actuator Bearings Spherical Roller Bearing




OEM TC R

3.5.2 (a) Indicator strip (b) Packing (c)Hardware items

Product Identification 100% Conformity to specifications

OEM TC / CC

R

3.5.3 Wiper Ring Product Identification 100% Conformity to specifications

OEM TC / CC

R

3.5.4 Chevron Packing Product Identification 100% Conformity to specifications

OEM TC / CC

R

3.5.5 Rudder Locking Valve Product Identification 100% Conformity to specifications

OEM TC R

3.5.6 Dowty Seal Product Identification 100% Conformity to specifications

OEM TC R

3.5.7 Banjo Coupling Product Identification 100% Conformity to specifications

OEM TC R

3.5.8 Male Stud Coupling Product Identification 100% Conformity to specifications

OEM TC R

3.5.9 Spring Feed Lubricator Product Identification 100% Conformity to specifications

OEM TC R

3.5.10 Self-sealing Coupling with Blanking cap


OEM TC R

3.6.0 SUPPLY TANK & RESERVE TANK ASSY (DRG. NO._____)

3.6.1 Spherical / Ball Valve

(i) Product identification 100% SOTR, Approved GA


OEM TC / CC

R

29


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

(ii) Pressure Test and Functional Checks on assembly

100% drawing, DBOM and manufacturing drawings / catalogue

Pressure test & Functional checks are satisfactory

IR W

3.6.2 Thermostat / Temperature switch


100% Conformity to specifications Calibration is indate.


R

(ii)Functional Test on assembly


IR W

3.6.3 Magnetic Level Switch


OEM TC R

(ii) Functional Test on assembly


IR W

3.6.4 Level gauge / Sight gauge

Product identification. 100% Conformity to specifications

OEM TC R



OEM TC / CC

R



3.6.6 Air Breather


OEM TC / CC

R

3.6.7 Charging Pump / Semi-Rotary Hand Pump

(i) Product identification. 100% Conformity to specifications

OEM TC R



IR W

3.6.8 Three-way Valve


OEM TC / CC

R



IR W

3.6.9 Check Valve


OEM TC R



IR W

3.6.10 Filters


OEM R

30


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

3.6.11 Quick Change Coupling



OEM TC R

3.6.12 Hardware items


OEM TC R

3.6.13 Hydraulic MS Fittings (Passivated)


OEM TC / CC

R


100%


IR R

(iii) Pressure Test (1.5 times working Pressure, 30 mins)


IR W

(iv) Coating Thickness (other than passivated)

One test piece / lot

Test is satisfactory IR R

3.6.14 Junction Box


OEM TC R


100%


3.6.15 Limit Switch


OEM TC R

(ii) Functional Check on assembly


IR W

3.6.16 Spherical Plug Valve


OEM TC R



IR W

3.6.17 Door Joint


OEM TC R


100%


3.6.18 Test Actuator


OEM TC R



IR W

3.7.0 DISTRIBUTION BLOCK ASSEMBLY (DRG. NO. ____)

31


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

3.7.1 (a) Relief Valve

(b) Shut off valve




OEM TC R


Sampling Conformity to specifications

IR R

(iii) Pressure tests 100% Pressure Test is satisfactory

IR W

(iv) Coating thickness (Other than Passivated)

01 test piece / lot


3.7.2 Pump Stop Valve


OEM TC / CC

R



IR W

3.7.3 Cylinder Stop Valve


OEM TC / CC

R



IR W

3.7.4 Pilot Operated DC Valve


OEM TC / CC

R



IR W

3.8.0 EMERGENCY HAND PUMP ASSEMBLY (DRG. NO. ____)

3.8.1 Hand Pump

(i) Product identification 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings / catalogue


OEM TC / CC

R



IR W

3.8.2 Air Breather


OEM TC / CC

R

3.8.3 Hand Wheel


STC / CC R

3.8.4 Shock & Vibration Mounts with fasteners

Inspection 100% As per SQAP / Separately approved

QAP Form IV / I-note

R

3.9.0 PIPES FITTINGS (PIPING LAYOUT) (DRG. NO____)


(i) Product identification 100% SOTR, Approved GA drawing, DBOM and manufacturing


OEM TC / CC

R



32


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

3.9.2 MS Fittings & Adapters (Passivated)

(i) Product identification 100% drawings / catalogue


OEM TC / CC

R


100% Test is satisfactory IR R

(iii)Pressure test (1.5 times working Pressure, 30 mins)


IR W




3.9.3 Filter Product identification and Visual Inspection


OEM TC R

3.10.0 LUBRICATION ASSEMBLY (Drg No.___)

3.10.1 Motorized Lubrication Pump Assembly

Inspection 100% As per SQAP at Appendix-E Form IV / I-Note

R

3.10.2 Shock & Vibration Mount


Form IV / I Note

R

3.10.3 Stud Stand Pipe Adopter



OEM TC / CC

R

3.11.0 PORTABLE FLUSHING UNIT (Drg. No: __)

3.11.1 Flushing Unit Assembly

Inspection 100% As per Separately approved QAP Form IV / I-note

R

3.12.0 ESP POWER UNIT ASSEMBLY & SUPPLY OIL TANK (DRG. NO. ______)

3.12.1 Vane Pump (i) Product identification. 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings / catalogue


OEM TC / CC

W



IR W

3.12.2 Hydraulic MS Fittings & Adapters (Passivated)


OEM TC / CC

R


100% Test is satisfactory IR R

(iii) Pressure test (1.5 times working Pressure, 30 mins)


IR W

33


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS




IR R



OEM TC / CC

R

(ii)Polymer Identification 100% Conformity to specifications


3.12.4 Oil Cooler

Inspection 100% As per separately approved QAP Form IV / I-note

R

3.12.5 Filter Product identification 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings / catalogue


OEM TC R

3.12.6 Solenoid Operated DC Valve


OEM TC / CC

R

3.12.7 Quick Change Coupling (Self-Sealing Coupling)


OEM TC R

3.12.8 Check Valve


OEM TC R



IR W

3.12.9 Thermostat / Temperature switch

(i) Product identification 100% Conformity to specifications. Calibration is indate.


R

(ii)Functional Checks on assembly


IR W

3.12.10 Magnetic Level Switch


OEM TC R



IR W

3.12.11 Level gauge / Sight gauge

Product identification. 100% Conformity to

specifications OEM TC R



OEM TC / CC

R


LTC R

3.12.13 Air Breather


OEM TC R

34


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

3.12.14 Three-way Valve


OEM TC / CC

R



IR W

3.12.15 Hardware items


OEM TC R

3.12.16 Shock & Vibration Mounts & fasteners

Inspection 100% As per SQAP / Separately approved

QAP Form IV / I-note

R

3.12.17 Hydraulic MS Fittings (Passivated)

(i) Product identification 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings / catalogue drawings


OEM TC R


100%


IR R

(iii) Pressure Test (1.5 times working Pressure, 30 mins)


IR W




IR R

3.12.18 Pressure Relief Valve


OEM TC / CC

R

3.12.19 Suction Strainer


OEM TC / CC

R

3.12.20 Test Actuator

(i)Product Identification 100% Conformity to specifications

OEM TC R

(ii)Functional Check on assembly


IR W

3.12.21 Pressure Gauge Panel

(i) Product Identification 100% Conformity to specifications

OEM TC R

(ii)Visual Inspection and Dimensional Inspection

100%

IR R

3.12.22 Note:- 1. Make of the items should be as per approved DBOM. 2. For imported components, following documents to be submitted:- (a) Bill of Lading / Shipping Bill / Airway Bill (b) Invoice by OEM or Country of Origin Certificate with Packing List (c) Bill for entry to warehousing (d) OEM Confirmation Certificate (e) Firm’s Guarantee certificate as per SOs 3. The inclusion of outsourced components / items under various categories viz. Imported, COTs, Bought-out & Sub-Contracted is to be as per Chapter 5 of QAD (available at DGQA website www.dgqadefence.gov.in) 4. Physical verification / Testing of all outsourced components may be undertaken during assembly.

http://www.dgqadefence.gov.in/

35


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

4.0.0 IN -PROCESS / SUB -ASSEMBLY INSPECTION

4.1.0 WELDING INSPECTION

4.1.1 WPS & PQR

Qualification of Procedure for various processes



WPS PQR R

4.1.2 WPQ

Performance Qualifications

100% WPQ Record

R

4.2.0 RUDDER BEARING ARRANGEMENT ASSEMBLY (DRG. NO.___)

4.2.1 Lower Bearing Housing and Upper Bearing Housing

(i) Visual Inspection and Dimensional Inspection after machining



IR R

(ii) Surface Finish 100% Conformity to

specifications IR R

4.2.2 Rudder Stock (Forging)



IR R

(ii) Surface Finish 100% Conformity to specifications

IR R

4.2.3 Rudder Stock Bearing Liners / Sleeves (Upper and Lower)



IR R


IR R

4.2.4 Inboard & Outboard Bearing



IR R


IR R

4.2.5 (a) Thrust Bearing (b) End Piece



IR R


IR R

4.2.6 Tiller

(i) Visual Inspection and Dimensional Inspection


IR R

36


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

after machining


IR R

4.2.7 Gland Follower



IR R


IR R

4.2.8 (a) Lock nut Tiller (b) Stud (for Lock nut-Tiller) (c) Stud for Gland Follower



IR R


IR R

4.2.9 Rudder




IR W

(ii) DPT of welding 100% DPT is satisfactory NDE Report

CHP for W

Testing to be done by ISNT/ASNT Level II or III qualified technician.

4.2.10 Hull Cartridge Structure



IR W

(ii) DPT of welding 100% DPT, MPT and UT are satisfactory

NDE Report

CHP for W

Testing to be done by ISNT/ASNT Level II or III qualified technician. (iii) MPT of weld joints 100% NDE

Report CHP for W

(iv) UT of critical weld joints

Critical Welds

NDE Report

CHP for W

4.2.11 Bedding Contact of Tiller to Rudder Stock

Blue Matching 100% Conformity to specifications. Min. 80% Bedding Contact

IR CHP for W

4.3.0 LINK TUBE ASSEMBLY / SYNCHRONISING LINK TUBE ASSEMBLY (DRG. NO. ____)

4.3.1 Link tube

Visual Inspection and Dimensional Inspection



IR R

4.3.2 Link end L.H. & R.H.



IR R

4.3.3 Bearing Retainer



IR R

37


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

4.3.4 Bearing Pin



IR R

4.3.5 Locking Plate



IR R

4.3.6 Support Plate for Bearing Pin



IR R

4.3.7 Link Tube Support Bracket



IR R

4.3.8 Final Assembly



IR CHP for W

4.4.0 POWER UNIT ASSY (DRG. NO.____)

4.4.1 Pump and Motor Mounting Bracket

(i)Visual Inspection and Dimensional Inspection after machining

100% SOTR, Approved GA drawing, DBOM, manufacturing drawings and approved ATP / FATs document


IR R

(ii) DPT of weld joints 100% Conformity to applicable standard / specifications

NDE Report

CHP for W


4.4.2 Sole Plate



IR R

(ii) DP Test of welding 100% Conformity to applicable standard / specifications

NDE Report

CHP for W


4.4.3 Manifold Block

Visual Inspection and Dimensional Inspection after machining



IR R


(i) Check the items as per assembly drawing


IR W

(ii) Visual Inspection and Dimensional Inspection as per assembly drawing


IR CHP for W

(iii) Shop floor test as per test procedure

100% Inspection is satisfactory

IR CHP for W

4.5.0 HYDRAULIC ACTUATOR / HYDRAULIC CYLINDER RAM ASSEMBLY (DRG NO. ____)

4.5.1 Tube for Cylinder / Cylinder Barrel


100% SOTR, Approved GA


IR R

38


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

after machining drawing, DBOM, manufacturing drawings and approved ATP / FATs document

4.5.2 Cross head Ram



IR R

4.5.3 Cylinder Rear end Cover



IR R

4.5.4 Cylinder Front End Cover



IR R

4.5.5 H- Beam/Guide Bar



IR R

4.5.6 Guide Plate / Guide Keep



IR R

4.5.7 Cod Piece




IR R

4.5.8 Bearing Bush and Plate



IR R

4.5.9 Cross Head Slipper



IR R

4.5.10 Guide Slipper



IR R


(i) Check assy. as per drawing


IR CHP for W

(ii) Check for movement and stroke length

100% Movement is satisfactory

IR CHP for W

(iii) Pressure Test @1.5 times of working pressure

100% Pressure test is satisfactory

IR CHP for W

4.6.0 SUPPLY TANK ASSEMBLY (DRG. NO___)

4.6.1 Tank (Fabrication)




IR R

mailto:[email protected]

39


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

(ii) DPT of welding 100% drawing, DBOM, manufacturing drawings and approved ATP / FATs document

DPT is satisfactory NDE Report

CHP for W





IR CHP for W

(ii) Leakage test as per approved FATs procedure

100% Nil leakages IR CHP for W

.

4.7.0 RESERVE OIL TANK ASSEMBLY (DRG. NO. ____)

4.6.1

Tank (Fabrication)




IR R


CHP for W





IR CHP for W

(ii) Leakage test as per approved FATs procedure

100% Nil leakages IR CHP for W

.

4.8.0 DISTRIBUTION BLOCK ASSEMBLY (DRG. NO. ____)


(i) Visual Inspection and Dimensional Inspection as per assembly drawing



IR CHP for W

(ii) Pressure Test @ 1.5 times of working pressure, 30 mins & Functional Test

100% Pressure Test and Functional Test are satisfactory

IR CHP for W

4.9.0 EMERGENCY HAND PUMP ASSEMBLY (DRG. NO.____)

4.9.1 Hand Pump Assembly




IR CHP for W

(ii) Functional Test 100% Functional Test are satisfactory

IR CHP for W

4.10.0 ESP POWER UNIT ASSEMBLY & SUPPLY OIL TANK (DRG. NO._____)

4.10.1 Bell Housing




IR R

mailto:[email protected]

40


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

(ii) DPT of welding 100% drawing, DBOM, manufacturing drawings and approved ATP / FATs document

DPT is satisfactory NDE Report

CHP for W


4.10.2 Tank



IR R


CHP for W


4.10.3 Manifold Block



IR R




IR CHP for W

(ii) Functional & Leakage test as per approved FATs procedure

100% Functional and Leakage Test are satisfactory

IR CHP for W

5.0.0 PRE-REQUISITE -FINAL INSPECTION (IFT)

5.1.0 TYPE TESTING OF HYDRAULIC SYSTEM (Actuators, Distributors, Valves, Power Pack, Pipelines and Other Hydraulic Components)

5.1.1 Endurance Run of Hydraulic System - 100Hrs uninterrupted

All functional parameters to be recorded

01 Unit SOTR, Approved GA drawing, DBOM, manufacturing drawings and approved ATP / FATs document

All parameters are satisfactory

Type Test Report

CHP for W

5.1.2 Tilt Test (unit is to run

for 01 hour with 20 tilt in each direction)

All functional parameters to be recorded

01 Unit All parameters are satisfactory

Type Test Report

CHP for W

5.1.3 Shock Analysis of Hydraulic system

Compliance to Shock Grade IN Shock Grade A / NSS II, as applicable, is to be proved

01 Unit Equipment meets IN Shock Grade A / NSS II, as applicable

NSTL(V) Report

CHP for R

5.1.4

Noise & Vibration

(i) Mechanical Vibration of Hydraulic System

01 Unit Vibration amplitude within limits specified in SOTR

LTC CHP for R

Reports to be forwarded to IHQ MoD(N) for validation / approval (ii)Structure Borne Noise

of Hydraulic System 01 Unit SBN meeting the

limits specified in SOTR

LTC CHP for R

(iii) Air Borne Sound Power radiated by Hydraulic System

01 Unit ABN meeting the limits specified in SOTR

LTC CHP for R

41


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

5.2.0 HYDRAULIC FATS

5.2.1 Test Bed Facility

Suitability as per FATs requirements


Test bed should be suitable for FATs

IR W

5.2.2 Internal FATs Report

All QA Checks Including Functional & Safety Parameters

100% Internal FATs completed satisfactorily

Internal FATs Report

CHP for R

5.2.3 FATs of Hydraulic System (Power Packs) - Proving Run 24 Hrs

(i) Verification of Type Test Report

100% Type Test Report is available

TT Report R



IR CHP for W

(iii) Functional & Safety Checks

100% Functional & Safety Checks are satisfactory

IR CHP for W

(iv) Noise & vibration Checks

100% Noise & Vibration checks are satisfactory

IR CHP for W

(v) Dispatch Clearance / Form IV (if manufactured by sub- vendor)

100% IR R

5.3.0 ELECTRICAL & ELECTRONICS COMPONENTS

5.3.1 Motor

Inspection 100% As per SQAP Form IV / I-note

R Integration trials of motor with MSP to be conducted at manufacturers place

5.3.2 Motor Starter Panel


R

5.3.3 Control Panel


R

5.3.4 ESS Test (for PWAs)

PWAs Testing 100% SOTR, Approved GA drawing, DBOM, manufacturing drawings and approved ATP

ESS Tests are satisfactory

ESS Report

R

5.3.5 Final Functional Test (For PWAs -DIP, DOP, AIP, AOP)

Functional Checks 100% Final functional

tests are satisfactory

Test Report CHP for W

5.3.6 Inter Unit Wiring Checks

Wiring checks Random Checks are

satisfactory Wiring Report

W

6.0.0 MISCELLANEOUS REQUIREMENTS

6.1.0 Submission of Draft Documentation

Checks of draft documentation

100% SOTR / PO Draft should be available

IR CHP for R

To be forwarded to IHQ MoD(N) for approval

6.1.1 Software Quality Software Testing 100% Separately Software testing is Form IV / I- R

42


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

Checks approved Software QAP

satisfactory note

6.1.2 Inspection of the test bed setup & Integrated System

As per IFT document 100% SOTR, Approved GA drawing, DBOM, manufacturing drawings and approved ATP / FATs document

Checks are satisfactory

IR W

6.1.3 TSP / TNC Compliance

Checks for compliance to TSP / TNC

100% SOTR, Approved GA drawing, DBOM, manufacturing drawings TSP / TNC minutes

Compliance to TSP / TNC minutes

Compliance Matrix

CHP for R

7.0.0 FINAL INSPECTION - IFT (MECHANICAL, HYDRAULIC & CONTROL SYSTEM)

7.1.0 Integrated Functional Trials of Mechanical, Hydraulic & Control System on OEM Test Bed / Stand

All functional parameters to be recorded. 100 Hrs for first set. 24 Hrs Production Run for balance sets.

100% SOTR, Approved GA drawing, DBOM, manufacturing drawings and approved ATP / IFATs document

Satisfactory completion of all trials. Liquidation of all defects / shortcomings observed during IFATs

IFATs Report

CHP for W

8.0.0 PRE-REQUISITE-ISSUE OF I & T CERTIFICATE / FORM-IV

8.1.0 OBS Items as per Purchase Order

Product identification and Visual Inspection

100% SOTR, Approved GA drawing, DBOM, manufacturing drawings and approved ATP / IFATs document

OBS are supplied as per PO

MTC and CC

W

8.1.1 Submission of ‘As Built' Drawings’

Verification and Stamping 100% As built drawings are complete and satisfactory

As built drawings

CHP for R

8.1.2 Submission of Approved Documentation

Verification and Stamping 100% Documentation is

complete Documentation

CHP for W

8.1.3 Liquidation of observations during

Liquidation of defects 100% All defects

liquidated IR W

43


SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

IFT ( If any)

8.1.4 Weight Recording

Weighing 100% To be within limits Weight Certificate

W

8.1.5 Painting & Preservation

Visual Inspection and Dry Film Thickness

100% Painting and DFT meets the specifications

IR W

8.1.6 Submission of FORM4 (I & T Certificate)

Correctness 100% FORM-4 P

NOTE:-

1. Equipment & accessories to be supplied should conform to specifications.

2. If Type Testing, EMI/EMC and ETT have already been done in earlier projects on identical units, it will not be done again & the reports of earlier tested units will be provided for review of Inspection Agency.

3. EMI / EMC test and ET will be done at Government/PSU test centers or Firm's lab if NABL accredited. 4. Material Testing to be done at NABL approved Lab. 5. NDT procedure to be approved by ASNT / ISNT Level III qualified person based on standards and acceptance criteria specified in SOTR / TSP and performed by

ASNT / ISNT Level II / Level III qualified person. For RT, the shooting sketch indicating Critical Test Regions and Test Regions to be submitted prior to testing. 6. The 'Bought out' items in the QAP are indicative only. The firm is required to categorically define the 'Bought out' / COTS items specific to their products in the

drawings. Items will be categorized as bought out or COTs in the QAP on the basis of approved drawings. Further, only finished products will be accepted as COTs and no raw material for manufacturing will be acceptable as a COTs item.

7. The QAP does not apply to items not in the scope of supply of the firm. Inspection of assemblies / sub-assemblies and other items which have not been included in the SQAP but form an important part of the system will also be undertaken.

8. Pressure testing of hydraulic fittings will be undertaken on assembly. All pressure testing specified in the QAP will be as per the approved ATP / FATs document.

9. Shooting sketch indicating critical test zones and test zones are to be submitted prior to testing. 10. The column 'Quantity as per P.O' has been left blank which has to be filled by the firm as per P.O while submitting QAP for approval. 11. Software QAP is to be approved by IHQ MoD (Navy). 12. The Functional Checks on assembly are to be undertaken at the earliest available opportunity (FATs / IFATs). 13. The defects observed during NDT of castings and forgings should be within the acceptable limits specified in the applicable standards.

44

Appendix - 'B'

Refers to Part-II of SQAP

STANDARD QUALITY ASSURANCE PLAN FOR MOTORS

SL. NO

MATERIAL/ COMPONENT/


QTY CHARACTERISTIS / TYPE OF CHECK

QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

VERIFIED BY QAE

REMARKS

1.0 DRAWINGS/DOCUMENTS/TYPE TESTS

1.01 Drawings Approved drawings 100% PO, SOTR, TNC Minutes & EED-Q-071 (R4) (whichever is relevant)

Same as reference documents

List of approved binding drawings

CHP for R Approval by Design Authority, Prof. Dte, Shipyard and Inspection Authority / Command HQ to be verified.

2.0 MATERIAL INSPECTION

2.01 (a) SS Shaft (b) Structural Steel for Plate

Mechanical properties and Chemical Composition

Sample Approved Drawings

Material grade std as per approved drgs

LTC (NABL Lab)

CHP for R Sample to be drawn in presence of QA rep

2.02

(a) SS Shaft (b) Structural Steel for Plate

UT

100% -do- -do- Certified by ASNT level - II Personnel

R

2.03 (a) Stamping (b) Copper Wire

(i) Visual Inspection (ii) Dimensional Inspection (iii) Mechanical, Chemical, Thermal and Electrical Properties

Sample

-do- -do- STC R

2.04 (a) Bearing Make / Type

(b) Shaft Seal

(c) Misc items viz. Cable Gland, Cooling Fan etc. As per PO / Approved Drawings

(i) Visual Inspection (ii) Dimensional Inspection

100% -do- -do- STC R

3.0 STAGE INSPECTION

3.01 Rotor & Stator (i) Visual Inspection (ii) Dimensional Inspection (iii)Calculation of air gap

100% -do-

Approved drawings

Firm’s QA Report / STC

R

3.02 Rotor Balancing 100% -do- -do- Firm’s QA Report

R

45

SL. NO




QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

VERIFIED BY QAE

REMARKS

4.0 ASSEMBLY

4.01 Motor Assembly Bill of Material items 100% Approved drawings

Firm Report IR W

5.0 TEST AND TRIALS

5.01 Type Tests (a) Insulation Resistance (Ambient & Hot) (b)Winding Resistance (Hot & Cold) (c) Temperature rise (d) Load test at 100%, 75% and 50 %. Determine Efficiency & PF (e) Starting Torque (f) Pull Out Torque (g) Starting Current and Run up Time (h) Reduced Voltage Test (j) Over Speed at 115% for15 minutes (k) Withstand Voltage (l) Oscilographic records of Starting Current at Full Load / No Load at Normal / Reduced Voltage (m) Phase Balance at Full Load / No Load Conditions. (n) Momentary Over-load Test at 110% for 15 sec. (p) Thermister Resistance (Ambient, Hot & Cold) (q) Hot Spot Sensing (r) IP (as applicable) (s) Direction of rotation (t) Earth Bonding (u)Protection Under Stall Condition

One motor of each frame size per lot

DEE Policy EED-Q-071-(R4) and approved drawing

Type test report

W

46

SL. NO




QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

VERIFIED BY QAE

REMARKS

5.02 Routine Tests (a) No load test (b) Over speed test at 115 % for 15 minutes (c)Short circuit test (d)Thermister resistance (ambient, hot and Cold) (e) Phase balance at no load (f)Starting torque (g)Winding resistance (Hot & Cold) (h)Space heater (where ever applicable) (j) IP (as applicable) (k)Direction of Rotation

All balance motors

EED-Q-071(R4) and approved drawing


Routine Test Report

W

5.03 General for all motors (a) Insulation test (ambient & hot) (b) High voltage test (c)Noise level test (d)Vibration test (e)Bearing check / SPM (f)Dimensional check (g)Weight check (h)Terminal / name plate check (j)Earth bond test. (k)Space heater (wherever applicable) (l)Withstood voltage

All motors EED-Q-071(R4) and approved drawing


Routine Test Report

W

5.04 Integration Trial As per DEE Policy One motor of each type with respective starter / control panel

DEE Policy DEE Policy IR W Starter motor integration trials to be conducted at motor manufacturer place as per IHQ policy EE/01/1-67/Power-18 dt 15 Jul 10. Only for new construction ships

47

SL. NO




QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

VERIFIED BY QAE

REMARKS

5.05 Type tests, ETT & EMI/EMC reports

Verification Prototype sample

PO

PO

Type test reports

CHP for R EMI / EMC Acceptance Test Plan duly vetted by NEC Mumbai

6.0 DOCUMENTATION

6.01 Documents for operation, maintenance and repair

Availability & verification 100% PO PO - CHP for R

7.0 PAINTING, PACKING AND PRESERVATION

7.01 Painting, Packing, Preservation and Marking

As per SOTR/PO

100% Critical SOTR / PO

CHP for W

NOTE:-

1. Type Test, EMI/EMC and Environmental test in accordance with EED-Q-071-(R4) / JSS-55555.2012(Rev. 3) is to be carried out after QA agencies, clearance and sealing of equipment. Post ET and EMI/EMC, checks will also be conducted by QA agencies. If Type Testing, EMI/EMC and ET has already been done in earlier projects on identical units, it will not be done again & the reports of earlier tested units will be provided for review of Inspection Agency. In case of any difficulty/discrepancy in carrying out the above, matter be referred to IHQ MoD(N)/DEE within 10 days of receipt of approved QAP under intimation to HQ DQA(WP). 2. EMI EMC test and ET will be done at NABL Lab. EMI/EMC Acceptance Test Plan is to be duly vetted by NEC Mumbai. 3. Equipment & Accessories to be supplied should conform to specifications. 4. Starter cum control panel is to be procured / manufactured only from Naval approved vendor as mentioned in IHQ MoD (N)/DEE Co mpendium of Vendors 2015 No. EE-50-30(REV-2) dated 29 Jun 15.

48

Appendix - 'C' Refers to Part-II of SQAP

STANDARD QUALITY ASSURANCE PLAN FOR AC STARTERS AND CONTROL GEAR

SL. NO

MATERIAL/ COMPONENT/ DRG.

NO / QUALITY ACTIVITY

QTY CHARACTERISTCS / TYPE OF CHECK

QUANTUM OF CHECK

REFERENCE DOCUMENT

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

VERIFIED BY QAE

REMARKS

1.0.0 DRAWINGS/DOCUMENTS/TYPE TESTS

1.01

Drawings Approved drawings 100% PO, SOTR, TNC Minutes andEED-Q-071(R4) (whichever is relevant)

Same as reference document


CHP for R

Approval by design authority, Prof Dte, Shipyard and Insp. Authority / Command HQ to be verified.

2.0.0 MATERIAL INSPECTION

2.01 Steel for fabrication Dimensions Measurement

Approved Drawings

Material grade std. as per approved drawings

IR CHP for R Sample to be drawn in presence of QA rep

Surface finish Visual IR

Physical & Chemical Properties

Sample LTC (NABL Lab)

COTS ITEMS

2.02 Air Break Switch Type No. Verification Make / Type as per Approved Drawings

Standard as per approved drawings

STC R

Current Rating

Voltage Rating

2.03 Air Circuit Breaker Type No. Verification -do- -do- STC R

Current Rating

Voltage Rating

2.04 Air Break Contactor Type No Verification -do- -do- STC R

Current Rating

Coil Voltage

Auxiliary Contacts

2.05 Bus Bar Cross Section Verification -do- -do- STC R

Conductivity

Bend Test

Tensile Test

Chemical composition

2.06 Cable Voltage Grade Verification Make / Type as per Approved Drawings


STC R

Colour

Nominal cross section area

Thickness of insulation

IR Value

49

SL. NO




QUANTUM OF CHECK

REFERENCE DOCUMENT

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

VERIFIED BY QAE

REMARKS

Cond. Resistance

2.07 Current Transformer Type of CT (Insul- ation material used)

Verification -do-

-do- STC R

Terminal Markings / Dimensions

Polarity

Ratio

Burden (Not applicable for special purpose CTs)

Knee pt. (Applicable for special purpose CTs Voltage)

ALF (Applicable for special purpose CTs)

ISF (Applicable for special purpose CTs)

2.08 Control Transformer Ratio Verification -do- -do- STC R

Tapping

Rating

Terminal Markings

2.09 Busbar Support Flammability Verification -do-

Approved drawings

STC R

Water absorption

Density

Tensile Strength

Compressive st.

Flexural Strength

Impact Strength

Breakdown Voltage

Arc Resistance

Dimension

2.10

HRC Fuse & Fuse Base

Type No Verification

Make / Type as per Approved Drawings

Approved drawings

STC R

Current Rating

Voltage Rating Continuity

2.11 MCCB Type No. Verification -do-

-do- STC R

Current Rating

Voltage Rating

2.12 MCB Type No. Verification

-do-

-do- STC R

Current Rating

50

SL. NO




QUANTUM OF CHECK

REFERENCE DOCUMENT

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

VERIFIED BY QAE

REMARKS

Voltage Rating

2.13 Meters (Voltmeters, Ammeter, Frquency meter, KWH meter, Transducer etc.)

Range / Make Verification -do-

-do-

STC R

CTR/PTR/Shunt

Type of Movement

Calibration/ Accuracy

2.14 Neoprene Gasket/Conductive gasket/EMI shielding as applicable

Dimensions Verification

-do-


STC R

Hardness

Flame Test as applicable

2.15 Voltage Transformer / Potential Transformer

Ratio Verification -do-

-do- STC R

Burden

Accuracy Class

Polarity

No of Phases

Voltage factor

Insulation Level

Functional checks

2.16 Relays Model /Type No. Verification -do-

Approved drawings

STC R

Relay Details

Auxiliary contacts

Operational Checks

2.17 Space Heater Rating Verification -do- -do- STC R

Wattage

2.18 Thermostat Range Verification -do- -do- STC R

Rating

2.19 Timer Type No Verification -do-


STC R

Voltage Rating

Aux. Contacts

2.20 Miscellaneous Electrical items (Bulbs, Lamp Holder, Resistors, PB, Actuators, Diodes, Bridge Rectifiers, Switch)

Make Verification -do- -do- STC R

Rating

2.21 Core Balanced CTs Make Verification -do-

-do- STC R

Type

Rating

Primary Operating Current

51

SL. NO




QUANTUM OF CHECK

REFERENCE DOCUMENT

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

VERIFIED BY QAE

REMARKS

CT Secondary Current

Tripping Time

Tripping Range

2.22 Soft Starter Make Verification -do- -do- STC R

Type

2.23 Cable Glands Dimensional Verification -do- -do- STC R

2.24 Bare PCBs / PWBs ESS Test 100% -do- As per extant policy (para 2 of footnote relevant)

STC / NABL Report

R

3.0 INPROCESS INSPECTION

3.01. Fabrication/ bending Shearing / cut-outs welding

Visual Visual Check

Approved Drgs


IR CHP for R

Dimension Physical verification

For welding distance b/n welding spots.

Physical verification

3.02 Surface preparation & painting

Visual VI -do- Same as reference document

IR CHP for R

Shade VI

Coating thickness Conduct

Adhesion Conduct

3.03

Wiring Wiring Size Visual Verification

-do- -do- IR CHP for R

Continuity Ckt Health By Test

4.0 ASSEMBLY

4.01 Panel Assembly Dimension VI Approved Drgs


IR W

Gland Plate assembly

Base Plate assembly

Panel Coupling

4.02 Visual Inspection Overall Dimension and weight

VI -do- -do- IR W

Mounting Arrangement of components

Wiring arrangement and ferruling, Gasket fixing, Cable Gland and Tally plate details

5.0 TEST & TRIALS

5.01 Functional checks Functional checks at No load & Full Load

By Test EED-Q-071(R4)

Same as reference

IR W Full load test by Current Injection

52

SL. NO




QUANTUM OF CHECK

REFERENCE DOCUMENT

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

VERIFIED BY QAE

REMARKS

IR Test before and after HV Test

document method

HV Test

Milivolt drop test on Power Circuit in excess of 100A, Earth bond and Temperature rise (applicable for Panels with Busbar)

5.02 Type tests, ETT & EMI/EMC reports

Availability & verification

Prototype sample

PO, Approved drawings, EED-Q-071(R4)


Type test reports

CHP for R As per para 2 of footnote relevant

6.0 DOCUMENTATION

6.01 Documents for Operation, Maintenance & Repair

Availability & verification

100% PO PO - CHP for R

7.0 PAINTING, PACKING AND PRESERVATION

7.01 Packing, Painting, Preservation and Marking

As per SOTR/PO 100% Critical

Visual PO CHP for W

NOTE:-

1. Type Test, EMI/EMC and Environmental test in accordance with EED-Q-071-(R4)/JSS-55555.2012(Rev. 3) is to be carried out after QA agencies, clearance and sealing of equipment. Post ET and EMI/EMC, checks will also be conducted by QA agencies. If Type Testing, EMI/EMC and ET have already been done in earlier projects on identical units, it will not be done again & the reports of earlier tested units will be provided for review of Inspection Agency. In case of any difficulty/discrepancy in carrying out the above, matter be referred to IHQ MoD(N)/DEE within 10 days of receipt of approved QAP under intimation to HQ DQA(WP).

2. EMI EMC test and ETT will be done at NABL Lab. EMI/EMC Acceptance Test Plan is to be duly vetted by NEC Mumbai.

3. ESS test (Thermal Cyling, Random Vibration and Burn in / Endurance ) as per DQA(N) policy vide letters 66301/Policy-07/DQA(N)/QA-07 dated 09 Aug 16.

4. Equipment & Accessories to be supplied should conform to specifications.

5. Starter cum Control Panel is to be procured /manufactured only Naval approved vendor as mentioned in IHQ MoD(N) / DEE Compend ium of Vendors 2015 No. EE-50-30(Rev 2) dated 29 Jun 15.

6. Conformal coating of PCBs to be done as per DQA(N) policy letter 580930/DQA(N)/EL dated 17 Feb 14.

53

Appendix - 'D' Refers to Part-II of SQAP

STANDARD QAP FOR STEERING GEAR ELECTRONICS AND CONTROL SYSTEM

SR. NO

COMPONENTS QTY AS

PER P.O


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE NORMS

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

1.0 DRAWINGS / DOCUMENTS VERIFICATION

1.1 GA Drawings along with DBOM & Binding Data





CHP for R


1.2 Manufacturing Drawings Verification of manufacturing drawings with reference to the approved GA drawings and DBOM for completeness and sufficiency of data to undertake production and process inspections.




CHP for R

2.0 RAW MATERIAL INSPECTION

2.1 Steel plates for fabrication of all Panels / Consoles:- • Steering gear panel - Bridge • Steering gear panel - OPS Room • Steering gear panel - MCR • ESP starter panel with ACOS • Angle transmitter unit • Central control panel (Port / Stbd) • Local control unit (Port / Stbd) • Starter panel (Port / Stbd) • ACOS panel (Port / Stbd) • Power supply unit

(i)Material Identification & Stamping


Raw material confirm to given specifications

IR W


01 sample per lot

Physical, mechanical and chemical properties meet the laid down specifications


54

SR. NO

COMPONENTS QTY AS

PER P.O


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE NORMS

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

(Port / Stbd) • Junction Boxes (Port / Stbd) • Control transformer (Port / Stbd) • Any other panel not included in the list

3.0 INSPECTION OF MAJOR OUTSOURCED ITEMS

3.1 Shock Mounts (Not part of IFT)


Form IV / I-note

R

3.2 Motor Starter Panels Inspection 100% As per SQAP Form IV / I-note / Dispatch clearance / Test Report

R

3.3 Motors Inspection 100% As per SQAP Form IV / I-note / Dispatch clearance / Test Report

R

3.4 Rudder Feedback Unit (i) Product Identification 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings

Material confirms to approved drawing

IR R

(ii) Functional test 100% Functional tests are satisfactory

OEM TC/CC and IR

W

4.0 IN-PROCESS/SUB - ASSEMBLY INSPECTION

4.1 All Panels and Consoles

(i) Visual & Dimensional Inspection


No visible damages; Dimensions are as per the drawing

IR W

(ii) Painting (DFT) 100% Compliance to specifications

IR R

4.2 Electronic units / Components / PCBs / Modules - Indigenously manufactured / assembled

ESS (a) PCB level (b) Module / sub-unit level (c) Unit / cabinet level

100% SOTR, Approved GA drawing, DBOM manufacturing drawings and

Electronics items should clear ESS

IR CHP for W

ESS programme is to be drawn up by vendor based on the equipment design and

55

SR. NO

COMPONENTS QTY AS

PER P.O


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE NORMS

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

approved ESS Programme

approved by DQA(WP)

5.0 ENVIRONMENTAL AND TYPE TEST

5.1 Assemblies and Sub-assemblies of the Steering Electronics and Controls System

Pre-type test (applicable for units to undergo type testing)

01 unit of each type

SOTR, Approved GA drawing, DBOM and manufacturing drawings

Functional test is satisfactory

Type Test Report

CHP for W

Environmental Tests 01 unit of each type

SOTR, Approved GA drawing, DBOM manufacturing drawings, JSS55555 and approved test plan

ETs are satisfactory

ET Report CHP for R

EMI/EMC Test 01 unit of each type

EMI/EMC test is satisfactory

EMI/EMC Test Report

CHP for R

POST-type test (applicable for units to undergo type testing)

01 unit of each type

Functional test is satisfactory

Type Test Report

CHP for W

6.0 FINAL INSPECTION / FACTORY ACCEPTANCE TRIALS

6.1 1.Local Control Unit 2.ESP starter panel with ACOS 3.Lub Pump Starter Panel 4.ACOS panel

Visual Inspection 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings, EED-Q-071(R4)

Compliance to approved drawings and DBOM

IR W

Completeness of the panel 100% All hardware as per approved drawings and DBOM are installed

IR W

Overall connection, installation & dimensions

100% Compliance to approved drawings and DBOM

IR W

Functional Checks at No Load & Full Load

100% Functional checks is satisfactory

IR W Full load test by current injection method or with motor at motor manufacturer’s premises as per DEE Policy

Ingress protection check Sample Required degree of protection is achieved

IR R To be done at NABL accredited lab

56

SR. NO

COMPONENTS QTY AS

PER P.O


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE NORMS

FORMAT OF

RECORD

ACTION BY QAE

REMARKS


100 % Insulation resistance is satisfactory

IR W

HV Test 100% HV test is satisfactory

IR W

Milivolt drop test if power circuit is in excess of 100A

100% Test is satisfactory

IR W

Earth bond test and temperature rise test

100% Tests are satisfactory

IR W Applicable for panels with bus bar

Painting - Visual Inspection and DFT


IR W

Weight measurement 100% Weight as per specifications

IR W

6.2 1. Power Supply Unit 2. Central Control Panel 3. Bridge Console 4. OPS Room Console 5. MCR Console 6. Angle Transmitter Unit 7. Junction Box 8. Control Transformer

Visual Inspection 100% SOTR, Approved GA drawing, DBOM and manufacturing drawings, EED-Q-071(R4)

Compliance to approved drawings and DBOM

IR W

Completeness of the panel 100% All hardware as per approved drawings and DBOM are installed

IR W

Overall connection, installation & dimensions

100% Compliance to approved drawings and DBOM

IR W

Functional Checks at No Load & Full Load

100% Functional checks is satisfactory

IR W Full load test by current injection method or with motor at motor manufacturer’s premises as per DEE Policy

Ingress protection check Sample Required IP is achieved

IR R Tests at NABL accredited lab


100 % Insulation resistance is satisfactory

IR W

HV Test 100% HV test is satisfactory

IR W

57

SR. NO

COMPONENTS QTY AS

PER P.O


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE NORMS

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

Painting - Visual Inspection and DFT


IR W

Weight measurement 100% Weight as per specifications

IR W

7.0 Software Refer software QAP for Integrated Electronics system of steering gear system

8.0 Documentation Verification 100% As per SOTR and PO

As per SOTR and PO

IR CHP for R

9.0 Packing & Preservation Visual Inspection 100% As per SOTR and PO

As per SOTR and PO

IR CHP for W

10.0 Submission of FORM4 / DGS&D(S)-84

Correctness 100% FORM-4/

DGS&D(S)

-84

P

NOTES:-

1. Type Test, EMI/EMC and Environmental test in accordance with EED-Q-071-(R4)/JSS-55555.2012(Rev. 3) is to be carried out after QA agencies, clearance and sealing of equipment. Post ET and EMI/EMC, checks will also be conducted by QA agencies. If Type Testing, EMI/EMC and ET have already been done in earlier projects on identical units, it will not be done again & the reports of earlier tested units will be provided for review of Inspection Agency. In case of any difficulty/discrepancy in carrying out the above, matter be referred to IHQ MoD(N)/DEE within 10 days of receipt of approved QAP under intimation to HQ DQA(WP).

2. EMI / EMC test and ET will be done at NABL Lab. EMI/EMC Acceptance Test Plan is to be duly vetted by NEC Mumbai.

3. ESS test (Thermal Cyling, Random Vibration and Burn in / Endurance ) as per DQA(N) policy vide letters 66301/Policy-07/DQA(N)/QA-07 dated 09 Aug 16. ESS to be undertaken in NABL accredited Lab.

4. Equipment & Accessories to be supplied should conform to specifications.

5. Conformal coating of PCBs to be done as per DQA(N) policy letter 580930/DQA(N)/EL dated 17 Feb 14.

58

Appendix - ‘E’ Refers to Part-II of SQAP

STANDARD QUALITY ASSURANCE PLAN FOR MULTIPOINT LUBRICATING PUMP ASSEMBLY

SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

1.0.0 DRAWINGS / DOCUMENTS VERIFICATION

1.1.0 GA Drawings along with DBOM & Binding Data





CHP for R


1.2.0 Manufacturing Drawings Verification of manufacturing drawings with reference to the approved GA drawings & DBOM for completeness and sufficiency of data to undertake production & process inspections.




CHP for R

--

1.3.0 Type test / ET / EMI / EMC reports

Availability & verification 100% PO & SOTR / TNC Minutes/ JSS 55555

Equipment should be tested in the past and relevant certificate is available

Type/ Qualification test reports

CHP for R

Type / qualification test are to be conducted if not undertaken earlier or test certificate not held or equipment has undergone changes

2.0.0 SECTION I - RAW MATERIAL INSPECTION

2.1.0 MANUFACTURED ITEMS

2.1.1 1. Pump body 2. Pump element 3. Reservoir 4. Base plate

(i) Material Identification & Stamping



IR W

(ii) Mechanical properties & Chemical Composition

01 sample/ heat / lot



2.2.0 BOUGHTOUT ITEMS

2.2.1 Gear box Product Identification 100% SOTR, Approved GA drawing, DBOM, manufacturing


OEM TC / CC

R

59

SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

drawings and catalogue

2.2.2 Motor Inspection 100% As per SQAP Form IV / I-note

R

2.2.3 Motor Starter Panel Inspection 100% As per SQAP Form IV / I-note

R

2.2.4 Brass Tubes (i) Material Identification & Stamping

100% SOTR, Approved GA drawing, DBOM, manufacturing drawings and catalogue


IR W

(ii) Mechanical properties & Chemical Composition

01 sample/ lot



(iii)Pressure testing 100% Pressure testing is satisfactory

IR W

2.2.5 1. Grease Nipple 2. Limit Switch 3. Tale Tell Rod

Product Identification 100% SOTR, Approved GA drawing, DBOM, manufacturing drawings and catalogue


STC R

3.0.0 IN PROCESS INSPECTION

3.1.0 1. Pump body 2. Pump element 3. Reservoir 4. Base plate

Visual and Dimensional Inspection



IR R

3.2.0 Plunger Pump Assembly on Body

Leak tightness and Dimensional Inspection


IR R

3.3.0 Plunger Pump Alignment Alignment checks and Dimensional Inspection


IR R

4.0.0 PRE-REQUISITE FINAL INSPECTION

4.1.0 TYPE TESTING

4.1.1 Endurance Test - 24 hrs Record all functional parameters


All parameters satisfactory. No leakages in system

IR W

4.1.2 Tilt Test - 30 mins at 15o tilt on both side

Record all functional parameters

01 unit All parameters satisfactory. No leakages in system

IR W

60

SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS

4.1.3 Vibration Test Record vibration signatures

01 unit To be within specified limits

4.1.4 Shock Test Environmental Shock Test

01 unit Test is satisfactory

NSTL Report

R

4.1.5 SBN Test, if applicable Record SBN 01 unit To be within specified limits

IR W

4.1.6 Shock Test Environmental Shock Test

01 unit Test is satisfactory

NSTL Report

R

5.0.0 FINAL INSPECTION / FACTORY ACCEPTANCE TRIALS

5.1.0 Preliminary Test (i) Visual and Overall Dimensional Inspection



IR W

(ii) Functioning of tell-tale hole


IR W

(iii) Functioning of limit switch


IR W

(iv) Functioning of grease filling valve


IR W

(v) Preliminary run to check following:-

• Motor / cam speed

• Abnormal noise

• Excessive vibration

• Abnormal heating

• Leakages

100% Inspection is satisfactory. No abnormal noise, excessive vibration and leakages observed

IR W

5.2.0 Test without load (i) Measure Discharge 100% SOTR, Approved GA drawing, DBOM, manufacturing drawings and app. FATs document

Discharge is satisfactory

IR CHP for W

(ii) Leakage from joints 100% No leakages IR CHP for W

(iii)Noise and vibration test 100% To be within limits

IR CHP for W

5.3.0 Full Load Test (i) Measure Discharge 100% Conformity to specifications

IR CHP for W



IR CHP for W

5.4.0 Proving Run Test - 06 hrs

(i) Measure Discharge 100% Conformity to specifications

IR CHP for W


61

SL. NO.



QTY AS

PER P.O.


QUANTUM OF CHECK

REFERENCE DOCUMENTS

ACCEPTANCE CRITERIA

FORMAT OF

RECORD

ACTION BY QAE

REMARKS


IR CHP for W

6.0.0 Weight Recording

Weighing 100% SOTR, Approved GA drawing

To be within limits

Weight Certificate

W

7.0.0 Painting Visual Inspection 100% SOTR & PO Painted as per specifications

IR R

8.0.0 Packing, Preservation and Marking

Visual Inspection 100%

SOTR & PO Preserved, Marked and Packed as per specifications

IR R

9.0.0 Submission of FORM4 / DGS&D(S)-84

Correctness 100% FORM-4/ DGS&D(S)-84

P

NOTE:-

1. Equipment & accessories to be supplied should conform to specifications.

2. If Type Testing, EMI/EMC and ET have already been done in earlier projects on identical units, it will not be done again & the reports of earlier tested units will be provided for review of Inspection Agency.

3. EMI / EMC test and ETT will be done at Government/PSU test centers or Firm's lab if NABL accredited. 4. Material Testing to be done at NABL approved Lab. 5. NDT procedure to be approved by ASNT / ISNT Level III qualified person based on standards and acceptance criteria specified in SOTR / TSP and performed by ASNT / ISNT Level II / Level III qualified person. For RT, the shooting sketch indicating Critical Test Regions and Test Regions to be submitted prior to testing. 6. The 'Bought out' items in the QAP are indicative only. The firm is required to categorically define the 'Bought out' / COTS items specific to their products in the drawings. Items will be categorized as bought out or COTs in the QAP on the basis of approved drawings. Further, only finished products will be accepted as COTs and no raw material for manufacturing will be acceptable as a COTs item.

7. The QAP does not apply to items not in the scope of supply of the firm.

8. Inspection of assemblies / sub-assemblies and other items which have not been included in the SQAP but form an important part of the system wi ll also be undertaken. 9. The column 'Quantity as per P.O' has been left blank which has to be filled by the firm as per P.O while submitting QAP for approval.

MINISTRY OF DEFENCE / DGQA STANDARD QUALITY … Gear Rev -01.pdf · 2 ASTM E 446 RT for steel...

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Transcript of MINISTRY OF DEFENCE / DGQA STANDARD QUALITY … Gear Rev -01.pdf · 2 ASTM E 446 RT for steel...